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Summary of Contents for Kodiak LS3
- Page 1 KODIAK MARINE Marine Operators Manual 2.4L 4.3L 5.7L 6.0L AND 6.2L LS3 ENGINES KEM EQUIPMENT INC 10800 SW HERMAN RD TUALATIN, OR. 97062 PHONE (503) 692-5012 FAX (503) 692-1098 KM 10701 REV A...
- Page 3 IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation that, if not avoided, could result in damage to engine or property. NOTE provides other helpful information that does not fall under the warning or caution categories.
- Page 4 WARNING: PROPER USE Any unauthorized modifications to or use of this engine outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the engine. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings...
- Page 5 WARNING: BATTERY GROUNDING: Do not connect battery ground or any accessory ground wires to the starter mounting bolts. Doing so can cause a loose bolt situation over time that will cause starter failure or a possible damaged engine block. WARNING: CARBON MONOXIDE EXPOSURE Carbon Monoxide is an odorless, colorless and tasteless gas that cannot be smelled, seen or tasted.
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Page 6: Table Of Contents
Table of Contents Introduction Page Safety Summary How to use this manual Engine Identification Page 10-13 Engine ID Warranty Card Component ID Pre Operational Inspection Page 14-16 Engine fluid levels Belts Battery connections Hoses Flame Arrestor Malfunction Indicator Light (MIL) Starting the Engine Page 17-18 Starting Mode Fuel injection... - Page 7 Fuel Injection System Page 31-32 Fuel Filter Fuel Recommendation Fuel Type Fuel Quality Changes Power Loss at Higher Elevations Ignition System Page 33 Troubleshooting Page 34-37 Engine Does Not Crank Engine Will Crank Intermittently When the Engine Makes a Stuttering or Chattering Noise Engine Cranks But Does Not Start Engine Runs Hot Clear Flood Mode...
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Page 8: Introduction
Always observe required scheduled maintenance activities as outlined. Never attempt to correct problems or repairs for which you are not qualified. At the end of this manual, you will find a list of qualified Kodiak Marine service dealers to assist you in your area. -
Page 9: How To Use This Manual
How to Use this Manual This manual is designed to help you get to know your engine and become familiar with it’s various controls. During instruction, you will learn how to take care of your engine and what services need to be performed to keep it in excellent running condition. -
Page 10: Engine Identification
The engine model number and serial number are required when seeking information concerning the engine and/or ordering replacement service parts. This manual covers the 2.4L 4.3L 5.7L 6.0L and the 6.2L LS3 Marine Engines. Fill in the information from your engine in the above representation of the engine tag for future reference. -
Page 11: Component Id
Component Identification... - Page 12 These illustrations show the general location of engine controls and their functions. These illustrations will help identify where these parts are located on the engine. Locations will vary from engine to engine.
- Page 13 Parts and Service Replacement parts can be obtained through your local Kodiak engine dealer. Kodiak dealers are equipped to perform major and minor repairs. They are anxious to see that all of your maintenance and service needs are quickly and courteously completed.
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Page 14: Pre Operational Inspection
Remove the key from the ignition prior to any engine check or operation. Do not energize any engine prior to performing any of the following. Your KODIAK Marine Engine was inspected and test ran before leaving the factory. Before operating a new engine, you must follow any pre-operational instruction. -
Page 15: Malfunction Indicator Light (Mil)
Check the exterior of the heat exchanger. Follow and fix any leaks before continuing. 11. Check the alternator belt for any extra play; adjust as necessary. Does not apply to all engines. 12. Tighten all loose nuts and bolts. Check for any loose pieces and tighten as necessary. - Page 16 The second indicator is the Check Gauges light. This bulb will illuminate when a non-emissions related issue occurs. Items that can cause these codes are high or low oil pressure and coolant temperature and various power relay operation, system voltage etc. The lighting of this fault indicator would indicate to the operator that the gauges for oil pressure and coolant temperature should be checked immediately and action taken to eliminate engine damage.
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Page 17: Starting The Engine
STARTING THE ENGINE Prior to starting the engine the following must be performed. 1. Check engine oil level. 2. Check for fuel leaks. 3. Run bilge blower for a minimum of 10 minutes. 4. Check Coolant level. 5. Check bilge for excess water before starting engine. WARNING: The bilge can accumulate explosive fumes. -
Page 18: Starting Mode Fuel Injection
STARTING MODE – FUEL INJECTION With the ignition switch in the ON position, before engaging the starter, the ECM energizes the fuel pump relay for 10 seconds allowing the fuel pump to build pressure. The ECM uses the engine coolant temperature (ECT), the throttle position (TPS), and the manifold absolute pressure (MAP) sensors to determine the proper air/fuel ratio for starting. -
Page 19: Stopping The Engine
STOPPING THE ENGINE NORMAL CONDITIONS Let the engine idle for at least one minute prior to stopping the engine to reduce residual heat in engine components. Not doing this will not harm anything, but gives the engine a chance to reduce the temperature of many components. STOPPING THE ENGINE UNDER ABNORMAL CONDITIONS (Overheating) 1. -
Page 20: Maintenance Instructions
MAINTENANCE INSTRUCTIONS CAUTION: Neglecting proper maintenance can cause premature component failures. Initial Start Up Maintenance The initial start-up checks must be made before entering the engine into service. Please refer to the Maintenance Schedule on page 26 and perform the initial start- up operations in the sequence shown in column 1. -
Page 21: General Engine Specifications
2.4L/147 GENERAL ENGINE SPECIFICATIONS ENGINE 2.4L TYPE DISPLACEMENT 2405cc / 147 CID VALVE CONFIGURATION SINGLE O/H CAM VALVE LIFTERS HYDRAULIC FOLLOWER BORE X STROKE INCHES 3.44X3.94 MAIN BEARING CAPS 2 BOLT BALANCE METHOD INTERNAL INTAKE MANIFOLD SIDE DRAFT FIRING ORDER 1-3-4-2 OIL CAPACITY W/FILTER 4.5 QUARTS... - Page 22 4.3L/ 262 GENERAL ENGINE SPECIFICATIONS ENGINE 4.3L TYPE DISPLACEMENT 262 CID VALVE CONFIGURATION PUSH ROD VALVE LIFTERS HYDRAULIC ROLLER BORE X STROKE INCHES 4.00 X 3.48 MAIN BEARING CAPS 2 BOLT BALANCE METHOD EXTERNAL FIRING ORDER 1-6-5-4-3-2 OIL CAPACITY W/FILTER 4.5 QUARTS FUEL TYPE GASOLINE...
- Page 23 5.7L/350 GENERAL ENGINE SPECIFICATIONS TYPE L-31 DISPLACEMENT 5.7L 350ci VALVE CONFIGURATION OHV TWO PER CYL VALVE LIFTERS HYD ROLLER BORE X STROKE 4.00 IN X 3.48 IN MAIN BEARING CAPS 2 BOLT BALANCE METHOD EXTERNAL FIRING ORDER 1-8-4-3-6-5-7-2 OIL CAPACITY W/O FILTER 6 QTS FUEL TYPE GASOLINE...
- Page 24 6.0L/ 364 GENERAL ENGINE SPECIFICATIONS TYPE DISPLACEMENT 6.0L 364ci VALVE CONFIGURATION OHV TWO PER CYL VALVE LIFTERS HYD ROLLER BORE X STROKE 101.6 mm x 92 mm MAIN BEARING CAPS 6 BOLT BALANCE METHOD INTERNAL/EXTERNAL FIRING ORDER 1-8-7-2-6-5-4-3 OIL CAPACITY W/O FILTER 6 QTS FUEL TYPE GASOLINE...
- Page 25 6.2L LS3/376 GENERAL ENGINE SPECIFICATIONS Engine 6.2L TYPE DISPLACEMENT 376 CID VALVE CONFIGURATION OVERHEAD VALVES VALVE LIFTERS HYDRAULIC ROLLER BORE X STROKE INCHES 103.25 X 92MM INTAKE MANIFOLD COMPOSITE FIRING ORDER 1-8-7-2-6-5-4-3 FUEL SYSTEM FUEL INJECTED OIL CAPACITY W/REMOTE FILTER 5.5 QTS...
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Page 26: Maintenance Schedule
MAINTENANCE SCHEDULE SERVICE INTERVAL ENGINE CHECK POINTS EVERY 25 EVERY 50 EVERY 75 EVERY 100 EVERY 150 EVERY 200 EVERY 300 EVERY 400 DAILY HOURS HOURS HOURS HOURS HOURS HOURS HOURS HOURS GENERAL MAINTENANCE PRIOR TO ANY SERVICE OR MAINTENANCE ACTIVITY Inspect fuel system for leaks Inspect engine for fluid leaks Check engine oil... -
Page 27: Changing Engine Oil And Filter
CHANGING ENGINE OIL AND FILTER Under normal operating conditions, the engine oil and filter must be changed every 100 hours or every 12 months whichever occurs first. Use of premium quality oil and filters is recommended. The oil and filter should be changed more often if the engine is operating in severe conditions, such as dirty areas, or during cold weather. -
Page 28: Oil Filter
Ensure the old filter gasket is removed prior to installing the new filter. The Kodiak GM Powertrain engines use an AC Delco (or equivalent) oil filter as original equipment. An equivalent oil filter must be used when servicing the engine (see Engine Specifications starting on page 20 for the recommended oil filter for your engine). -
Page 29: Cooling System
COOLING SYSTEM KEM Equipment and GM Powertrain recommends the use of DEX COOL coolant in all engines. A 50/50 mixture is recommended. WARNING: Never remove the heat exchanger cap under any condition while the engine is operating. Failure to follow these instructions could result in damage to the cooling system, engine, or cause personal injury. -
Page 30: Heat Exchanger
NOTE: Make sure the belt tensioner is within the proper operating range. Most Kodiak engines utilize serpentine belts on the front of the engine; others use V belts. This type of belt system incorporates a belt-tensioning device that keeps the belt at the proper tension. This belt should be checked routinely for cracks or ‘checking’... -
Page 31: Fuel Injection System
FUEL INJECTION SYSTEM CAUTION: Failure to change the fuel system filter as recommended can result in premature failure of fuel injection system components. WARNING: Use extreme care when changing the fuel filter. Gasoline is highly flammable and under pressure. It should not be exposed to open flame, sparks, or hot engine components. -
Page 32: Fuel Type
2.4L 4.3L 5.7L 6.0L ENGINES Unleaded 87 Octane or better fuel is recommended. Lower octane fuels will reduce overall engine performance. Maximum Ethanol content is 10%. 6.2L LS3 ENGINE PREMIUM 91 MINIMUM OCTANE RECOMMENDED Fuel Quality Changes NOTE: Sudden changes in fuel quality, including geographical regions may effect engine operation. -
Page 33: Ignition System
10 minutes prior to cranking the engine. Type of Ignition System The ignition on Kodiak engines are controlled by an ECM, some use a distributor and some are distributorless. Turning or moving the distributor on engines so equipped, will not change the ignition timing. -
Page 34: Troubleshooting
/ warning. These problems usually develop as a result of neglected periodic maintenance. Whenever engine performance appears less than normal in any area, you should consult with your KODIAK dealer immediately. Do not wait for a problem to develop. Careful attention to periodic/regular maintenance will prevent most problems. -
Page 35: Engine Does Not Crank
Engine Does Not Crank WARNING: Make sure there are no fuel leaks before going any further. Clean up any spills and always work in a well-ventilated area. WARNING: To avoid any electrical injuries always replace any broken wires before proceeding. WARNING: The bilge can accumulate explosive fumes. -
Page 36: Engine Runs Hot
WARNING: Use extreme care when changing the fuel filter. Gasoline is highly flammable and under pressure. It should not be exposed to open flame, sparks, or hot engine components. Allow the engine to cool to ambient temperature prior to changing fuel filters. WARNING: Fuel is under HIGH pressure, consult dealer before servicing fuel system. -
Page 37: Emissions
CAUTION: DO NOT add coolant or water to any engine that has become overheated until the engine cools. Adding coolant or water to an extremely hot engine can result in a cracked block or cylinder head. The following items may cause the engine to overheat. •... -
Page 38: Storage
STORAGE (Lay-Up) ONE MONTH 1. Check coolant protection and fluid levels. 2. Add proper amount of marine formula Stabil fuel additive or equivalent to the fuel tank. 3. Start the engine 4. Treating the engine with a fogger is not recommended as this will damage the catalytic converters installed in the exhaust stream. -
Page 39: Periodic Maintenance Inspections
Periodic Maintenance Inspections 100, 300, 500, 700, 900, Hour Inspection WARNING: Make sure key is not in ignition and no electrical equipment is energized prior to any engine check or operation. Do not energize engine prior to performing the following steps. 1. - Page 40 6. Check charge and fluid level of battery. (Inspect connections for corrosion, and clean as necessary). 7. Check flame arrestor (Make sure that it is cleaned replaced as necessary). 8. Inspect the exterior of the heat exchanger (clean if necessary). 9.
- Page 41 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and KEM Equipment, Inc. / Kodiak Marine are pleased to explain the emission control system warranty on your 2011 model year inboard/stern drive engine. In California, new inboard/stern drive engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.
- Page 42 KEM Equipment Inc. / Kodiak Marine according to Subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
- Page 43 (7) KEM Equipment, Inc. / Kodiak Marine is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part.
- Page 44 The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if KEM Equipment, Inc. / Kodiak Marine demonstrates that the engine has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part.
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Page 45: Warranty
Marine dealer. This limited warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period. • Kodiak Marine will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period. - Page 46 • GROWTH OF MARINE ORGANISMS ON MOTOR SURFACES, EXTERNAL OR INTERNAL DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIES WARRANTIES: Kodiak Marine DISCLAIMS ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE INBOARD, REVENUE, OR THE EQUIPMENT IN, WHICH THE INBOARD IS...
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Page 47: On Board Diagnostic (Obd) System Check
ON BOARD DIAGNOSTIC (OBD) MEFI CONTROLLED MARINE ENGINE Fire, Shock, and Burn Danger: When performing any WARNING: diagnostics or service work use caution. This system has extreme fuel pressures and a high voltage ignition. Electronic controls contain static-sensitive parts. Observe CAUTION: the following precautions to prevent damage to these parts. - Page 48 : Verify that the engine cranks. ATTEMPT TO START THE ENGINE -If the engine does not crank, refer to SPN 66001 or SPN 66002 (if equipped). If the engine is not equipped with an ECM controlled starter relay, repair the starting system.
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Page 49: Diagnostic Codes
DIAGNOSTIC ERROR CODES: SPN 100 SPN Descriptors SPN 100 FMI 3: Engine Oil Pressure (EOP) Sensor Circuit Voltage Above Normal or Shorted High SPN 100 FMI 4: Engine Oil Pressure (EOP) Sensor Circuit Voltage Below Normal or Shorted Low SPN 100 FMI 17: Engine Oil Pressure (EOP) Sensor Data Valid But Below Normal Range-Least Severe Level SPN 105 SPN Descriptors... - Page 50 SPN 627 SPN Descriptor SPN 627 FMI 15: System Voltage Data Valid But Above Normal Range-Least Severe Level SPN 627 FMI 17: System Voltage Data Valid But Below Normal Range-Least Severe Level SPN 630, 65580, 65581, 65582 SPN Descriptors SPN 630 FMI 13: Cal Memory Out of Calibration SPN 65580 FMI 12: CPU Bad Intelligent Device or Component SPN 65581 FMI 12: MHC Failure Bad Intelligent Device or Component SPN 65582 FMI 12: NV RAM Failure Data Erratic, Intermittent or Incorrect...
- Page 51 SPN 65560 SPN Descriptors SPN 65560 FMI 9: CAN Bus Governor Command Abnormal Update Rate SPN 65561, 65562 SPN Descriptors SPN 65561 FMI 0: Oxygen Sensor Bank A Sensor 1 Data Valid But Above Normal SPN 65561 FMI 1: Oxygen Sensor Bank A Sensor 1 Data Valid But Below Normal SPN 65561 FMI 3: Oxygen Sensor Bank A Sensor 1 Voltage Above Normal or Shorted High SPN 65561 FMI 4: Oxygen Sensor Bank A Sensor 1 Voltage Below Normal or...
- Page 52 SPN 65601 FMI 2: Throttle Position (TP) Sensor 2 Data Erratic, Intermittent or Incorrect SPN 65602 FMI 2: Throttle Position (TP) Sensor 1 Data Erratic, Intermittent or Incorrect SPN 65610 FMI 2: Throttle Position (TP) Sensor 1 and 2 Data Erratic, Intermittent or Incorrect SPN 65604, 65605, or 65613 SPN Descriptors...
- Page 53 SPN 66001 FMI 3: Starter Relay Low Side Driver Voltage Above Normal or Shorted High SPN 66001 FMI 5: Starter Relay Low Side Driver Current Below Normal or Open Circuit SPN 66003 SPN Descriptor SPN 66003 FMI 3: Malfunction Indicator Lamp (MIL) Driver Voltage Above Normal or Shorted High SPN 66003 FMI 5: Malfunction Indicator Lamp (MIL) Driver Current Below Normal or Open Circuit...
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Page 54: Service Dealer Locations
UNITED STATES Alaska Idaho Anchorage Boise Silver Streak 907-344-6151 Whitewater Marine 208-377-5110 Professional Marine 907-562-2471 Lewiston Cordova Riverview Marina/ Custom Weld 800-859-0356 Harbor Hydraulics 907-424-3472 Michigan North pole Arctic Marine 907-488-5242 Marne Wasilla Marne Camp & Cruise 616-677-1274 Valley Diesel and Marine 907-373-2613 Wasilla Arctic Cat 907-376-5845 Montana Billings... - Page 55 Oregon (Continued) Canada Mulino Squeeky's Marine 503-632-3257 British Columbia Oregon City Chilliwack, BC Oregon City Marine 503-656-4276 Cascade Supply & Marine 800-663-2269 Portland Ventures River Boats 604-824-1498 Advanced Marine 503-762-2294 Richmond, BC Pacific Power Boats 503-288-9350 California Marine 604-278-1880 Sigler Marine 503-252-5431 Salem Alberta Dennis' Boat Shop 503-363-2898...
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